JBA 40-3016 - Manual

INSTALLATION INSTRUCTIONS
* Installation Recommendation: JAB recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-3016
2002 Chevrolet Avalanche
8.1L 2/4wd
RECOMMENDED TOOLS:
reciprocating saw or hack saw
pry bar
9/16 deep socket
ratchet
pair of channel lock pliers
anti-seize
spray lubricant or penetrating oil
B.
PARTS LIST:
A. Muffler 1
B. Tail pipe 1
C. Tip 1
D. Muffler hanger clamp 1
E. Tail pipe hanger clamp 1
F. Gusset filler plate 1
A. C.
D.
E.
F.
1. Remove and inventory JBA exhaust.
TO START:
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. Using the reciprocating saw, cut tail
pipe at the rear of the muffler.
Remove tail pipe.
4. At the front of the muffler, cut through
the welds and gusset. Remove muffler.
Cut left side of gusset loose to allow
for adjustment later.
8. Slip tail pipe hanger clamp (E) over
tail pipe (B) and insert hanger into
factory rubber isolator.
7. Insert tail pipe (B) into muffler (A).
14. After installation, it is recommended
that all clamps be retightened.
15. Lower the vehicle and reattach the
negative battery cable.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperatures
start to rise.
2) Use Anti-seize on threads of clamps.
12. Completely weld the front of the
muffler (A) to the converter pipes.
Install the gusset filler plate (F) and
weld in place.
13. Tack weld all slip joints in three spots
9. Install muffler hanger clamp (D) at
the rear of the muffler. Align tailpipe (B)
properly and secure.
5. Install new muffler (A). Slip muffler
onto converter pipes with minimum
overlap. Tack weld in place.
10. Slip tip (C) onto tail pipe (B).
6. Install tail pipe (B) from the rear of
vehicle.
11. Align the tip properly and tighten
clamp.